Cushioned orthotic

Abstract

An orthotic is disclosed. The orthotic may include a cushioning layer configured to extend from at least the metatarsal region to the proximal heel region, the cushioning layer having a heel region with a protruding heel piece integrally molded as part of the cushioning layer. The orthotic may also include an outer shell layer fixedly coupled to the cushioning layer, the outer shell layer extending longitudinally from at least the medial cuneiform-first metatarsal joint region to the calcaneus bone region of the user, the outer shell layer configured to receive the protruding heel piece.

1 . An orthotic, comprising:
 a covering layer on the top surface;   a foam cushioning layer fixedly coupled to the covering layer, the foam cushioning layer configured to extend from at least the proximal metatarsal region to the proximal heel region, the cushioning layer being at its thinnest towards the proximal region and thickest at the proximal heel region,   the cushioning layer having a protruding heel piece integrally molded as part of the cushioning layer at the proximal heel region, and   an upturned medial flange extending towards the proximal heel portion, wrapping around to the opposite lateral side, and tapering towards the distal forefoot portion;   an outer shell layer fixedly coupled to the cushioning layer, the outer shell layer configured to extend longitudinally from at least the medial cuneiform-first metatarsal joint region to the calcaneus bone region of the user,   the outer shell layer further having an upturned flange on the medial side, parallel to the upturned medial flange of the cushioning layer,   an enclosure defining a aperture therethrough at the heel region, the enclosure configured to receive the integral protruding heel piece of the cushioning layer, and   an inner shell insert layer operably attached between the cushioning layer and the outer shell layer, the inner shell insert layer extending from at least the medial cuneiform-first metatarsal joint region to the talus-navicular joint region of the user.   
     
     
         2 . An article of manufacture comprising:
 a display; and   a set of pre-manufactured orthotic removably disposed on the display, the set of pre-manufactured orthotics including a plurality of different orthotic models, the plurality of orthotic models including models with different respective lengths and models with different respective levels of arch support, wherein the plurality of orthotic models further comprises   a first model with a shortest length, a softest cushioning layer, and a lowest level of arch support;   a second model with the shortest length, the softest cushioning layer, and a higher level of arch support;   a third model with the shortest length, a firmer cushioning layer, and the lowest level of arch support;   a fourth model with the shortest length, the firmer cushioning layer, and the higher level of arch support;   a fifth model with a second length longer than the shortest length, the softest cushioning layer, and the lowest level of arch support;   a sixth model with the second length, the softest cushioning layer, and the higher level of arch support;   a seventh model with the second length, the firmer cushioning layer, and the lowest level of arch support;   an eighth model with the second length, the firmer cushioning layer, and the higher level of arch support;   a ninth model with a third length longer than the second length, the softest cushioning layer, and the lowest level of arch support;   a tenth model with the third length, the softest cushioning layer, and the higher level of arch support;   an eleventh model with the third length, the firmer cushioning layer, and the lowest level of arch support;   a twelfth model with the third length, the firmer cushioning layer, and the higher level of arch support;   a thirteenth model with the longest length, the firmer cushioning layer, and the lowest level of arch support;   a fourteenth model with the longest length, the firmer cushioning layer, and the higher level of arch support.   
     
     
         3 . An orthotic comprising:
 a cushioning layer having a heel region with a protruding heel piece integrally molded as part of the cushioning layer; and   an outer shell layer fixedly couple to the cushioning layer, the outer shell layer having an enclosure defining a aperture therethrough at the heel region, the enclosure configured to receive the protruding heel piece.   
     
     
         4 . The orthotic of  claim 3 , further comprising:
 an inner shell layer operably attached between the outer shell layer, and the cushioning layer, the inner shell layer configured to underlie and support the arch region of the user.   
     
     
         5 . An orthotic comprising:
 a cushioning layer configured to extend from at least the metatarsal region to the proximal heel region, the cushioning layer having a heel region with a protruding heel piece integrally molded as part of the cushioning layer; and   an outer shell layer fixedly coupled to the cushioning layer, the outer shell layer extending longitudinally from at least the medial cuneiform-first metatarsal joint region to the calcaneus bone region of the user, the outer shell layer configured to receive the protruding heel piece.   
     
     
         6 . The orthotic of  claim 5 , wherein the orthotic is ¾ in length and extends forward from the outer shell layer. 
     
     
         7 . The orthotic of  claim 5 , wherein the orthotic is full length and extends forward from the outer shell layer. 
     
     
         8 . The orthotic of  claim 5 , further comprising:
 an inner shell layer operably attached between the outer shell layer, and the cushioning layer, the inner shell layer configured to underlie and support the arch region of the user.   
     
     
         9 . The orthotic of  claim 5 ,
 the inner shell layer configured to extend from at least the medial cuneiform-first metatarsal joint region to the distal end of the protruding heel piece.   
     
     
         10 . The orthotic of  claim 5 ,
 wherein the inner shell insert layer comprises a thermoplastic material.   
     
     
         11 . The orthotic of  claim 10 , wherein the thermoplastic material is thermoplastic urethane. 
     
     
         12 . The orthotic of  claim 5 , wherein the cushioning layer comprises a foamed material. 
     
     
         13 . The orthotic of  claim 12 , wherein the foamed material is thermoset polyurethane foam. 
     
     
         14 . The orthotic of  claim 5 , wherein the cushioning layer forms a heel cup at the proximal end. 
     
     
         15 . The orthotic of  claim 5 , the outer shell layer further comprising an upturned flanged on the medial side. 
     
     
         16 . The orthotic of  claim 5 , the outer shell layer further comprising a plurality of perforations in the mid portion of the outer shell layer. 
     
     
         17 . The orthotic of  claim 16 , wherein the perforations in the mid portion of the outer shell layer comprises a plurality of parallel slots extending from the medial side to the lateral side. 
     
     
         18 . An orthotic, comprising:
 a covering layer on a top surface;   a foam cushioning layer fixedly coupled to the covering layer,   the foam cushioning layer is configured to extend from at least the proximal metatarsal region to the proximal heel region, the cushioning layer being thinnest at the distal forefoot region and thickest at the heel region, the cushioning layer having an upwardly raised convex protrusion between the second and fourth metatarsal,   the cushioning layer further having a heel region with a protruding heel piece integrally formed as part of the foam cushioning layer, the protruding heel piece supporting the entire heel region and   an upturned medial flange extending towards the proximal heel portion, wrapping around to the opposite lateral side, and tapering towards the distal forefoot portion;   an outer shell layer fixedly coupled to the foam cushioning layer, the outer shell layer is configured to extend longitudinally from at least the medial cuneiform-first metatarsal joint region to the talus-navicular bone region, extending on either side around the calcaneus bone portion, the outer shell layer at the calcaneuous bone region cut out to form an enclosure defining a aperture therethrough for receiving the protruding heel piece, the outer shell layer extending on either side of the calcaneous region a pair of projecting extensions having a first end and a second end, the projecting extensions embracing the heel piece on either side with the first end and the second end terminating just behind the heel region,   the outer shell layer further having an upturned medial flange, parallel to the upturned flange of the cushioning layer; and   an inner shell insert layer operably attached between the cushioning layer and the outer shell layer, the inner shell insert layer extending from at least the medial cuneiform-first metatarsal joint region to the talus-navicular joint region of the user.   
     
     
         19 . An orthotic comprising:
 a cushioning layer having a heel region with a protruding heel piece integrally formed as part of the cushioning layer;   an outer shell layer fixedly coupled to the cushioning layer, the outer shell layer having a pair of projecting extensions, having a first end and second end, and embracing an enclosure defining a aperture therethrough at the heel region.   
     
     
         20 . The orthotic of  claim 19 , further comprising:
 an inner shell layer operably attached between the outer shell layer, and the cushioning layer, the inner shell layer configured to underlie and support the arch region of the user.   
     
     
         21 . An orthotic comprising:
 a cushioning layer having a heel region with a protruding heel piece integrally formed as part of the cushioning layer; and   an outer shell layer fixedly attached to the cushioning layer, the outer shell layer extending longitudinally from at least the medial cuneiform-first metatarsal joint region to the talus-navicular region, the outer shell layer having a pair of projecting extensions on either side of the calcaneus bone region, and an enclosure defining a aperture therethrough at the heel region for receiving the protruding heel piece of the cushioning layer.   
     
     
         22 . The orthotic of  claim 21 , the outer shell layer further having an upturned medial flange. 
     
     
         23 . The orthotic of  claim 21 , the pair of projecting extensions on either side of the calcaneus bone region are not joined at the back of the heel region. 
     
     
         24 . The orthotic of  claim 21 , the pair of projecting extensions on either side of the calcaneus bone region are joined at the back of the heel region. 
     
     
         25 . The orthotic of  claim 21 , further comprising an inner shell insert layer operably attached between the cushioning layer, and the outer shell layer. 
     
     
         26 . The orthotic of  claim 21 , the foam cushioning layer further comprising a raised convex protrusion at the distal forefoot region between the second to fourth metatarsal. 
     
     
         27 . An orthotic, comprising:
 a covering layer on a top surface;   a foam cushioning layer fixedly coupled to the covering layer,   the foam cushioning layer is configured to extend from at least the proximal metatarsal region to the proximal heel region, the cushioning layer is thinnest at the distal forefoot region and thickest at the heel region, the cushioning layer having an upwardly raised convex protrusion between the second and fourth metatarsal,   the cushioning layer further having a heel region with a protruding heel piece integrally formed as part of the foam cushioning layer, the protruding heel piece supporting the entire heel region and   an upturned medial flange extending towards the proximal heel portion, wrapping around to the opposite lateral side, and tapering towards the distal forefoot portion;   an outer shell layer fixedly coupled to the foam cushioning layer, the outer shell layer is configured to extend longitudinally from at least the medial cuneiform-first metatarsal joint region to the talus-navicular bone region, extending on either side around the calcaneus bone portion, the outer shell layer at the calcaneuous bone region cut out to form an enclosure defining a aperture therethrough for receiving the protruding heel piece, the outer shell layer extending on either side of the calcaneuos region a pair of projecting extensions having a first end and a second end, the projecting extensions embracing the heel piece on either side with the first end and the second end joined at the heel region,   the outer shell layer further having an upturned medial flange, parallel to the upturned flange of the cushioning layer; and   an inner shell insert layer operably attached between the cushioning layer and the outer shell layer, the inner shell insert layer extending from at least the medial cuneiform-first metatarsal joint region to the talus-navicular joint region of the user.   
     
     
         28 . A set of pre-manufactured cushioned orthotics comprising:
 a plurality of orthotics, the orthotics each having a cushioning layer and an arch support, the plurality of orthotics including orthotic models having at least two different respective lengths, orthotic models having at least two different respective levels of cushioning layer firmness, and orthotic models having at least two different respective levels of arch support.   
     
     
         29 . The set of pre-manufactured cushioned orthotics of  claim 28 , wherein at least two orthotic models of the same length have arch supports of different respective levels. 
     
     
         30 . The set of pre-manufactured cushioned orthotics of  claim 28 , wherein the different levels of arch support are made of a flexible polymer with different hardness. 
     
     
         31 . The set of pre-manufactured cushioned orthotics of  claim 28 , wherein at least two orthotic models of the same length have arch supports made of different materials. 
     
     
         32 . The set of pre-manufactured cushioned orthotics of  claim 31 , wherein the arch supports of different materials for an orthotic model of a particular length are substantially dimensionally identical. 
     
     
         33 . The set of pre-manufactured cushioned orthotics of  claim 28 , wherein no orthotics of the longest length have the softest cushioning layer. 
     
     
         34 . The set of pre-manufactured cushioned orthotics of  claim 28 , wherein the orthotics include ¾-length orthotics. 
     
     
         35 . The set of pre-manufactured cushioned orthotics of  claim 28 , wherein the orthotic models comprise fourteen different models with at least four different lengths, at least two levels of cushioning layer firmness, and at least two levels of arch support, wherein for at least one of the lengths there are at least four models comprising a first model series with a softest cushioning layer and lowest level of arch support, a second model series with a softest cushioning layer and a higher level of arch support, a third model series with a firmer cushioning layer and a lowest level of arch support, and a fourth model series with a firmer cushioning layer and a higher level of arch support. 
     
     
         36 . The set of pre-manufactured cushioned orthotics of  claim 35 , wherein the orthotic model series comprises of 14 different models, the models including:
 a first model with a shortest length, a softest cushioning layer, and a lowest level of arch support;   a second model with the shortest length, the softest cushioning layer, and a higher level of arch support;   a third model with the shortest length, a firmer cushioning layer, and the lowest level of arch support;   a fourth model with the shortest length, the firmer cushioning layer, and the higher level of arch support;   a fifth model with a second length longer than the shortest length, the softest cushioning layer, and the lowest level of arch support;   a sixth model with the second length, the softest cushioning layer, and the higher level of arch support;   a seventh model with the second length, the firmer cushioning layer, and the lowest level of arch support;   an eighth model with the second length, the firmer cushioning layer, and the higher level of arch support;   a ninth model with a third length longer than the second length, the softest cushioning layer, and the lowest level of arch support;   a tenth model with the third length, the softest cushioning layer, and the higher level of arch support;   an eleventh model with the third length, the firmer cushioning layer, and the lowest level of arch support;   a twelfth model with the third length, the firmer cushioning layer, and the higher level of arch support;   a thirteenth model with the longest length, the firmer cushioning layer, and the lowest level of arch support;   a fourteenth model with the longest length, the firmer cushioning layer, and the higher level of arch support.   
     
     
         37 . An article of manufacture comprising:
 a display; and   a set of pre-manufactured orthotic removably disposed on the display, the set of pre-manufactured orthotics including a plurality of different orthotic models, the plurality of orthotic models including models with different respective lengths and models with different respective levels of arch support.   
     
     
         38 . The article of manufacture of  claim 37 , wherein the orthotics models include a cushioning layer that are made of different respective levels of cushion firmness. 
     
     
         39 . The article of manufacture of  claim 37 , wherein the different levels of arch support are provided for different models of orthotic with the same length by having different arch support dimensions. 
     
     
         40 . The article of manufacture of  claim 37 , wherein the different levels of arch support are provided for different models of orthotics with the same length by using different arch support materials. 
     
     
         41 . The article of manufacture  claim 37 , wherein the arch supports for different models with the same length have substantially the same arch support dimension. 
     
     
         42 . The article of manufacture  claim 37 , wherein the different levels of arch support are provided for different models of orthotics with the same length by using different arch support materials. 
     
     
         43 . The article of manufacture  claim 42 , wherein the arch supports for different models with the same length have substantially the same arch support dimension. 
     
     
         44 . The article of manufacture  claim 37 , wherein the orthotics of different lengths and levels of arch support have substantially similar external designs. 
     
     
         45 . The article of manufacture  claim 37 , wherein the orthotics are ¾-length orthotics. 
     
     
         46 . The article of manufacture  claim 37 , wherein the orthotics models with the same size have substantially the same color scheme. 
     
     
         47 . The article of manufacture  claim 37 , wherein the orthotics models with the same support level have substantially the same color scheme. 
     
     
         48 . The article of manufacture  claim 37 , wherein all components of the orthotic models having the same length are substantially dimensionally identical.